2004 model year · NHTSA recalls, manufacturer TSBs, and owner forum reports · Updated September 2026
2004 · All trims · All engines
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According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2004 Toyota Highlander has 4 documented known issues, with 3 rated critical. The most serious are 2.4L 2AZ-FE Head Gasket and Head Bolt Thread Failure ($2,500-$5,000 repair), Radiator Internal Transmission-Cooler Failure — ATF/Coolant Cross-Contamination ("Strawberry Milkshake") ($400-$4,500 repair) and V6 Engine Oil Sludge / Gelling (1MZ-FE / 3MZ-FE) — Oil Pump Pickup Starvation ($500-$6,000 repair). Across all issues with published estimates, repair costs range from $200 to $6,000. DIY maintenance guides at au7o.io.
ELECTRICAL SYSTEM
Fujian Wanda Automobile Glass Industry (Wanda) is recalling certain aftermarket Replacement Windshields sold for use in 2014-2018 Toyota Highlander vehicles. The windshields have an attached wire harness that water may leak into, possibly causing damage to the vehicle's Engine Control Module (ECM).
ELECTRICAL SYSTEM:WIRING
Toyota Motor Engineering & Manufacturing (Toyota) is recalling certain model year 2016 Highlander vehicles manufactured May 26, 2016, to September 16, 2016. The brake fluid level sensor may not be connected to the wire harness, preventing the sensor from detecting the brake fluid level. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) No. 135, "Light Vehicle Brake Systems."
EQUIPMENT:OTHER:LABELS
Southeast Toyota Distributors, LLC (SET) is recalling certain model year 2016 Toyota Camry and Highlander, 2015-2016 Toyota Tundra, Scion FR-S, and tC vehicles. The Load Carrying Capacity Modification Label may not reflect the correct added weight of the installed accessories. As a result, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 110, "Tire Selection and Rims for Passenger Cars."
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According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2004 Toyota Highlander has 4 documented issues. The most frequently reported are: 2.4L 2AZ-FE Head Gasket and Head Bolt Thread Failure, Radiator Internal Transmission-Cooler Failure — ATF/Coolant Cross-Contamination ("Strawberry Milkshake"), V6 Engine Oil Sludge / Gelling (1MZ-FE / 3MZ-FE) — Oil Pump Pickup Starvation. Of these, 3 are rated critical and should be addressed promptly.
The 2004 Toyota Highlander has 4 known issues compiled from NHTSA recalls, manufacturer TSBs, and owner forum reports. 3 issues are rated critical: 2.4L 2AZ-FE Head Gasket and Head Bolt Thread Failure and Radiator Internal Transmission-Cooler Failure — ATF/Coolant Cross-Contamination ("Strawberry Milkshake") and V6 Engine Oil Sludge / Gelling (1MZ-FE / 3MZ-FE) — Oil Pump Pickup Starvation. Prospective buyers should inspect for these issues and factor potential repair costs into their purchase decision. Regular maintenance following the manufacturer's schedule helps prevent many common problems.
Repair costs for known Toyota Highlander issues range from $200 to $6,000, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, 2.4L 2AZ-FE Head Gasket and Head Bolt Thread Failure, typically costs $2,500-$5,000 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.
The 2001-2007 Highlander with the 2.4L 2AZ-FE 4-cylinder engine suffers from a design flaw where the aluminum head bolt threads strip out of the engine block. The plastic intake manifold traps heat against the block, causing thermal fatigue of the aluminum threads. This leads to… Repairs typically run $2,500-$5,000. Severity: high.
Content on this page was compiled with AI assistance using NHTSA complaints, TSBs, owner reports, and public automotive data. While we strive for accuracy, this information may contain errors. Always verify repair procedures and specifications with your vehicle's service manual or a qualified mechanic.
ELECTRICAL SYSTEM:SOFTWARE
Toyota Motor Engineering & Manufacturing (Toyota) is recalling certain model year 2014 Highlander and Highlander Hybrid vehicles. The affected vehicles may have improper software installed in the air bag electronic control unit (ECU) for the operation of the front passenger seat belt force limiter, and as a result, the force limiter may use the restraint setting designed for small occupants, such as those that weigh approximately 110 pounds, for all occupants regardless of their size. As such, some of these vehicles do not conform to Federal Motor Vehicle Safety Standard (FMVSS) number 208, "Occupant Crash Protection."
FUEL SYSTEM, GASOLINE:DELIVERY:HOSES, LINES/PIPING, AND FITTINGS
Toyota Motor Engineering & Manufacturing (Toyota) is recalling certain model year 2014 Toyota Avalon, Camry, Sienna, and Highlander and model year 2015 Lexus RX350 vehicles. Fuel may leak from the one of the fuel delivery pipes in the engine compartment.
+ 6 more recalls. Check all on NHTSA.gov
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Automatic-transmission Highlanders route ATF through a cooler integrated into the main radiator end tank. When the internal separator corrodes/cracks, engine coolant and transmission fluid mix, producing a pink 'strawberry milkshake' emulsion. Coolant in the ATF destroys the clut… Repairs typically run $400-$4,500. Severity: high.
The early Highlander 3.0L 1MZ-FE (and successor 3.3L 3MZ-FE) V6 is prone to engine oil sludge/gelling. Blow-by gases and moisture that fail to burn off (aggravated by short-trip driving, extended oil intervals and a PCV valve that clogs) turn the oil to a gel that coats the valve… Repairs typically run $500-$6,000. Severity: high.
A very common Highlander check-engine complaint is P0420 (Catalyst Efficiency Below Threshold, Bank 1) and its Bank 2 twin P0430. The downstream oxygen sensor readings track the upstream sensor too closely, indicating the catalytic converter is no longer scrubbing exhaust efficie… Repairs typically run $200-$2,500. Severity: medium.
